Modular powertrain component for hybrid electric vehicles

Abstract

A powertrain module includes an input, first bulkhead supporting the input for rotation, a hub, an electric machine including a stator connected to the first bulkhead and a rotor connected to the hub, a clutch for alternately opening and closing a drive connection between the input and the rotor, and a second bulkhead supporting the input for rotation.

The invention claimed is: 
     
       1. A powertrain module, comprising:
 an input; 
 a first bulkhead supporting the input; 
 a rotor hub; 
 an electric machine including a rotor rotationally fixed to the rotor hub; 
 a clutch for alternately opening and closing a drive connection between the input and the rotor; 
 a servo supported directly on the rotor hub for actuating the clutch; 
 a second bulkhead supporting the rotor hub; 
 a clutch hub secured to a radially outer surface of the input. 
 
     
     
       2. The module of  claim 1 , further comprising a flexplate connected to the rotor hub connectable to a torque converter casing. 
     
     
       3. The module of  claim 2 , further comprising:
 first spline teeth formed on the rotor hub; 
 second spline teeth formed on the flexplate and engageable with the first spline teeth. 
 
     
     
       4. The module of  claim 1 , wherein the clutch hub is connected with a spline to the radially outer surface of the input. 
     
     
       5. The module of  claim 1 , wherein the rotor further includes:
 a tube; 
 a first leg secured to the tube and supported by a first bearing on the first bulkhead for rotation; 
 a second leg secured to the tube and supported by a second bearing on the second bulkhead for rotation. 
 
     
     
       6. The module of  claim 1  wherein the rotor hub extends axially over a portion of the clutch hub. 
     
     
       7. The module of  claim 5 , further comprising
 the clutch further includes:
 first clutch plates secured to the clutch hub; 
 second clutch plates secured to the tube; and 
 
 the servo further includes:
 a piston supported on a radially outer surface of the rotor hub, moveable in a cylinder formed by 
 
 the tube, forcing the first and second clutch plates into mutual frictional engagement, thereby engaging the clutch; and
 a return spring forcing the piston away from the clutch plates, allowing the clutch plates to mutually disengage, thereby disengaging the clutch. 
 
 
     
     
       8. The module of  claim 7 , further comprising a balance dam supported on the radially outer surface of the rotor hub and located adjacent the cylinder. 
     
     
       9. The module of  claim 1 , further comprising a bearing fitted in the first bulkhead for supporting the input in rotation. 
     
     
       10. The module of  claim 1 , wherein the rotor hub further comprises lines communicating hydraulically with the servo. 
     
     
       11. The module of  claim 1 , wherein the second bulkhead further comprises
 a sump for containing hydraulic fluid; 
 a solenoid-actuated valve; and 
 lines communicating hydraulically with the solenoid-actuated valve. 
 
     
     
       12. A powertrain module, comprising:
 an input; 
 a first bulkhead supporting the input; 
 a clutch hub secured to the input; 
 a rotor hub extending axially along a radially outer surface of the clutch hub; 
 an electric machine including a rotor connected to the rotor hub; 
 a clutch for opening and closing a drive connection between the input and the rotor; 
 a clutch actuating servo supported on the rotor hub; 
 a second bulkhead supporting the rotor hub. 
 
     
     
       13. The module of  claim 12 , further comprising a flexplate connected to the rotor hub and connectable to a torque converter casing. 
     
     
       14. The module of  claim 12 , wherein the clutch hub is connected with a spline to the radially outer surface of the input. 
     
     
       15. The module of  claim 12 , wherein the rotor further includes:
 a tube; 
 a first leg secured to the tube and supported by a first bearing on the first bulkhead for rotation; 
 a second leg secured to the tube and supported by a second bearing on the second bulkhead for rotation. 
 
     
     
       16. The module of  claim 12  wherein the clutch hub is secured to a radially outer surface of the input. 
     
     
       17. The module of  claim 15  wherein:
 the clutch further includes:
 first clutch plates secured to the clutch hub; 
 second clutch plates secured to the tube; and 
 
 the servo further includes:
 a piston supported directly on a radially outer surface of the rotor hub, moveable in a cylinder formed by 
 
 the tube, forcing the first and second clutch plates into mutual frictional engagement, thereby engaging the clutch; and
 a return spring forcing the piston away from the clutch plates, allowing the clutch plates to mutually disengage, thereby disengaging the clutch. 
 
 
     
     
       18. The module of  claim 17 , further comprising a balance dam supported directly on the radially outer surface of the rotor hub and located adjacent the cylinder. 
     
     
       19. The module of  claim 12 , wherein the rotor hub further comprises lines communicating hydraulically with the servo. 
     
     
       20. The module of  claim 12 , wherein the second bulkhead further comprises
 a sump for containing hydraulic fluid; 
 a solenoid-actuated valve; and 
 lines communicating hydraulically with the solenoid-actuated valve.